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© 2018
burster
praezisionsmesstechnik gmbh & co kg
All rights reserved
Valid from:
22.05.2018
OPERATION MANUAL
Torque sensor
Model 8661
Manufacturer:
burster
praezisionsmesstechnik gmbh & co kg
Talstr. 1 - 5
76593 Gernsbach
Germany
Tel.: +49-7224-645-0
Fax.: +49-7224-645-88
Email: info@burster.com
www.burster.com
P.O. 1432
76593 Gernsbach
Germany
2742-BA8661EN-5170-051523

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  • Page 1 OPERATION MANUAL Torque sensor Model 8661 Manufacturer: © 2018 burster burster praezisionsmesstechnik gmbh & co kg praezisionsmesstechnik gmbh & co kg All rights reserved Talstr. 1 - 5 P.O. 1432 76593 Gernsbach 76593 Gernsbach Germany Germany Valid from: 22.05.2018 Tel.: +49-7224-645-0 Fax.: +49-7224-645-88...
  • Page 2 Furthermore, burster assumes no liability for direct, indirect or incidental damages as well as consequential or other damages arising from the provision and use of the present documentation.
  • Page 3 of 74...

  • Page 4: Table Of Contents

    4.1 Preparing for installation ........................18 4.2 Mechanical installation ........................19 4.2.1 Installation using mounting block ..................19 4.2.2 Free-floating installation ......................21 Torque sensor model 8661 with analog connection ................23 5.1 Electrical connection ........................23 5.1.1 Power supply .........................23 5.1.2 Connector pin assignments (standard sensor, 1 range) ............23 5.1.3 The connections in detail ......................24...
  • Page 5 5.2.3 Speed limits .......................... 28 5.2.4 Check function ........................28 USB version of the torque sensor model 8661 ................... 29 6.1 Electrical connection ........................29 6.1.1 Power supply ........................30 6.1.2 USB 2.0 pin assignment ....................... 30 6.1.3 Ground connection........................ 31 6.1.4 Wiring ............................
  • Page 6 9.1.1 General information ......................65 9.1.2 Details ...........................65 9.2 Dual-range sensor ...........................67 9.2.1 Switching between ranges (dual-range sensor) ..............67 9.2.2 Possible range extension of the nominal torque ..............67 9.2.3 Switching between measurement range ................67 9.2.4 Connector pin assignments (dual-range sensor, not USB) ..........67 9.2.5 Connection diagram (dual-range sensor, not USB) ..............68 9.2.6 Status display (dual-range sensor) ..................69 10 Calibration and adjustment ........................70...

  • Page 7: Safety Instructions

    Safety instructions On the torque sensor model 8661 and in this manual the following symbols warn about risks. Symbols in this manual 1.1.1 Signal words The following signal words are used in the operation manual according to the specified hazard classification.

  • Page 8: General Safety Instructions

    General safety instructions The torque sensor model 8661 uses state-of-the-art engineering and is safe to operate. However, if the torque sensor model 8661 is not used or operated as intended, it may present a hazard. DANGER Danger of electric shock!

  • Page 9: Introduction

    8661 transmits all measurement signals via USB. Both the low mass of the torque sensor model 8661 and its high torsional rigidity are an advantage when measuring dynamic torques. However, you need to pay attention to the torsion spring constant and the sensor’s cut-off frequency with such measurements.

  • Page 10: Environmental Conditions

    • Avoid radiant heat or cooling from one side. • Protect the torque sensor model 8661 from moisture. • The torque sensor model 8661 is not resistant to the effects of chemicals. Do not use the torque sensor model 8661 in a corrosive environment.

  • Page 11: Scope Of Delivery

    Please note the following when sending the torque sensor model 8661 in for repair: • If there is a problem with the torque sensor model 8661, please attach a note to the sensor case summarizing the fault.

  • Page 12: Conversions And Modifications

    If you open or dismantle the torque sensor model 8661 during the warranty period, this will void the warranty immediately. The torque sensor model 8661 does not contain any parts that are intended to be serviced by the user. Only the manufacturer's own qualified personnel are permitted to open the torque sensor model 8661.

  • Page 13: Definitions

    Diagram 1: Test side Drive side The drive side is the opposite end to the measurement end. The torque sensor model 8661 is also mechanically connected at this side. This side normally has the larger moment of inertia. You will see these markings on the drive side of the torque sensor model 8661:...
  • Page 14 You can use the torque sensor model 8661 to measure both clockwise and counterclockwise torques. If the torque is exerted in an anticlockwise direction (looking at the measurement end), you will get a negative signal at the output. Diagram 4:...

  • Page 15: Device Design And General Information

    The measuring shaft is composed of torsion bar, strain gauges, instrumentation amplifier and power and signal transmission components. If the torque sensor model 8661 is fitted with the rotational speed or angular displacement option, an incremental encoder disk is also fitted for measuring rotational speed or angular displacement (see chapter 9.1 “Angle / speed measurement”...

  • Page 16: Principle Of Operation

    The electrical resistance of these strain gauges changes proportionally to their elongation. The torque sensor model 8661 has a total of four strain gauges. These are arranged as a Wheatstone bridge circuit and are supplied with a DC voltage by the electronics. The output voltage from the strain gauges changes in direct proportion to the measured torque.

  • Page 17: Interference

    Determination of the resonant frequency The resonant frequency of the entire test setup is related to the sensor’s spring constant “c” and to the two moments of inertia “J ” and “J ”, each with the connected molding body. Resonant frequency in Hz Moment of inertia 1 in kg Moment of inertia 2 in kg Spring constant in Nm / rad...

  • Page 18: Installation

    Preparing for installation Run-in period Before fitting the torque sensor model 8661 for the first time, we recommend turning the sensor by hand through several revolutions. This may be needed in order to distribute the lubricant evenly around the roller bearings of the torque sensor model 8661.

  • Page 19: Mechanical Installation

    8661-Z00X. Mounting blocks have the advantage of an extra locating pin to help align the torque sensor model 8661 easily. If the torque sensor model 8661 needs to be removed temporarily from the setup, the mounting block avoids any time-consuming realignment when it is refitted.
  • Page 20 At time of fitting, there must be no foreign matter, burrs or lubricants on these components. 2. Fit the torque sensor model 8661 on the mounting block. Use the locating pin to centre the torque sensor model 8661 on the mounting block then screw-fasten the sensor to the block.

  • Page 21: Free-Floating Installation

    The torque sensor model 8661 is positioned between two balanced half-couplings. Installed in this way, the torque sensor model 8661 and the two half-couplings form a full coupling. Hence it helps to compensate for the inevitable axial offset between the mechanical connections.
  • Page 22 At time of fitting, there must be no foreign matter, burrs or lubricants on these components. 2. Fit the half-couplings on the shaft ends of the torque sensor model 8661. Always use the entire clamping length of these couplings. If possible, fit the sensor starting from the test side.

  • Page 23: Torque Sensor Model 8661 With Analog Connection

    Electrical connection 5.1.1 Power supply The operating voltage is supplied to the standard model of the torque sensor model 8661 via the connecting plug. Alternatively, it is also possible to provide an external supply via the socket. CAUTION Never connect power via both connections simultaneously.

  • Page 24: The Connections In Detail

    Open collector output for rotational speed and angular measurement NOTICE Danger of excessive heating! When connected to a voltage source, the torque sensor model 8661 overheats. This overheating will permanently damage the torque sensor model 8661. Always use a pull-up resistor in the voltage source connection.
  • Page 25 Here the external voltage is superimposed on the internal voltage source. As a result, for example, you can connect the torque sensor model 8661 directly to a PLC input with positive logic (not for American PLCs). Using the same connection method you can reduce problems with transmission quality with longer cables.

  • Page 26: Running Cables

    Longer transmission paths up to approx. 10 m CAUTION Danger of excessive heating! When connected to a voltage source, the torque sensor model 8661 overheats. This overheating will permanently damage the torque sensor model 8661. Always use a pull-up resistor in the voltage source connection.

  • Page 27: Extension Cables

    • Make sure that cable cross-section is sufficient. Note: If you use extension cables it is not necessary to recalibrate the torque sensor model 8661. However, you will need to adjust the entire measuring chain. IMPORTANT: If a burster cable of type 99540-000F-05200XX is ordered with the sensor, a ceramic capacitor is supplied with the cable.

  • Page 28: Measurement

    Once the self-test has finished, all the LEDs light up solidly for about 1 s. 3. As soon as they go dark again, the torque sensor model 8661 switches into its normal operating state. It is now ready for use.

  • Page 29: Usb Version Of The Torque Sensor Model 8661

    Electrical connection The USB socket on the torque sensor model 8661 is fitted in the factory with a protective dust cap. Before putting the torque sensor model 8661 into use, this cap must be levered off with a suitable tool without being damaged.

  • Page 30: Power Supply

    Power supply After the torque sensor model 8661 is connected to the USB port, the sensor identifies itself as a “high power device”. In this case the device draws 495 mA from the USB port. Usually this is not a problem for desktop PCs.

  • Page 31: Ground Connection

    Wiring The main points to remember are: • The torque sensor model 8661 must be grounded via its assembly bolts. • The USB cable length should not exceed 2 m. For longer cables it may be necessary to connect an active USB hub in the cable link to avoid losing the USB connection.

  • Page 32: Software Digivision

    If the torque sensor model 8661 has been used before with DigiVision on your computer, the device is normally detected automatically. Otherwise you may need to add the torque sensor model 8661 to the device list. If the torque sensor model 8661 is not displayed, run the device detection process.

  • Page 33: Device Settings

    3. As soon as the torque sensor model 8661 is detected, it appears under its port. Device settings You can access the “Device settings” menu from the DigiVision device list. 1. Open the device list in DigiVision. 2. Select the torque sensor model 8661 and click “Parameterization”.

  • Page 34: Settings

    If the torque sensor model 8661 includes the speed/angle measurement option, you can switch between these two forms of measurement in this menu. If the torque sensor model 8661 is the optional dual-range version, you can also select here the measurement range you require. Chapter 9.2 “Dual-range sensor” on page 67 contains further information on dual-range sensors.

  • Page 35: Limits

    7.2.2 Limits The “Limits” tab is where you can set the torque sensor model 8661 limits you require. Select the level for the limit, the channel reference for this limit and whether you wish to monitor the measurement signal for ≥...

  • Page 36: Properties, Measurement Rate Etc

    You can use the “Properties” button to make additional general settings. For instance you can set here the measurement rate for the torque sensor model 8661. 1. Open the device list in DigiVision. 2. Select the torque sensor model 8661 and click “Properties”. 3. You can now configure additional general settings. 7.3.1 General information You can use the “Properties”...

  • Page 37: Selecting The Measurement Rate

    7.3.2 Selecting the measurement rate Two different acquisition modes are available. Different measurement rates (sampling rates) can be selected depending on the acquisition mode. Normal Measurement rates of between 0.1 and 20 measurements per second are possible here. SPOM (Speed optimized POlling Mode) Measurement rates of between 0.1 and 1000 measurements per second are possible here.

  • Page 38: Measurement-Mode Settings

    “Measurement mode” function. 1. Open the device list in DigiVision. 2. Select the torque sensor model 8661 and click „Start measurement mode…“. 3. Press the “Options” button. This opens the “Basic configuration” window. of 74...

  • Page 39: Basic Configuration

    7.4.1 Basic configuration In the “Basic configuration” tab you can specify how many channels you wish to display. You can also make various settings here for the display and presentation of the measurement curve. Diagram 27: Basic configuration 7.4.2 Channel settings The “Channel settings”...

  • Page 40: Trigger

    The default setting is to adopt the parameters from the torque sensor model 8661, although you can also make manual changes to any parameter. You can also define here the limits, measurement-curve colours and the colours and shapes of the symbols that can be shown in the graphs. You make these settings separately for each measurement channel.

  • Page 41: Documentation

    Maximum and minimum values (Max, Min) are shown in the area to the left of the graph. You can reset these values using the “R” buttons. Diagram 31: Display showing the measurement curves for torque, speed and mechanical power (8661-P001) of 74...
  • Page 42 In the multi-channel software version 8661-P100, you can switch between different views. 1. Click on “full-screen” to get a larger view of the measurement curve. This enlarges the individual graph to full-screen size during the measurement process. 2. Click on “Normal” to revert to the standard view.

  • Page 43: Start / Stop A Measurement

    Start / stop a measurement To start a DigiVision measurement based on a connected torque sensor model 8661 or another USB device, follow the steps below: 1. Select the torque sensor model 8661 from the device list and click “Start measurement mode...”...

  • Page 44: Measurement Reports

    4. To stop the measurement, click “Stop measurement” or press [F8]. The measurement can also be stopped using a trigger with a suitable stop condition. For further information about the trigger function, please refer to chapter 7.4.3 “Trigger” on page Measurement reports Note: If you wish to save the raw data for the measurement data reports, before starting measurement...

  • Page 45: Archive Viewer

    3. Various filters such as device type, date and channel no. can be used to reduce the number of reports displayed for a clearer picture. Select the required report by left- clicking on it. If you wish to select more than one report, hold down the [CTRL] key on your keyboard at the same time.

  • Page 46: Exporting Reports To Excel

    7.7.3 Exporting reports to Excel Note: To export the measurement reports in the Excel format you will need Microsoft Excel or an equivalent piece of software. 1. Once you have selected the measurement reports you require in the “Archive viewer”, click on "Export"...

  • Page 47: Print Reports

    7.7.4 Print reports 1. Once you have selected the reports you require in the “Archive viewer”, you can print them by clicking the "Print" button. 2. Now select how you want the reports printed. of 74...
  • Page 48 3. Click on “Next”. 4. Now specify how you want the data to be output. You have the option to choose a printer, print preview or output as a PDF document. 5. Click on “Start”. 6. The data is now output in the specified form. of 74...

  • Page 49: Software Digivision

    Software DigiVision System requirements Name Manufacturer / description Operating systems Windows Server 2003, Windows XP, Windows 7, Windows 8, Windows 10 Processor Pentium 1200 MHz minimum, Pentium 2.0 GHz recommended Graphics card At least VGA 800 x 600; minimum 256 colors At least 256 MB RAM (Windows XP), Memory at least 512 MB (Windows Server 2003, Windows 7)
  • Page 50 3. Double-click to choose a language and start installation. Note: If Microsoft .NET Framework 4.0 is not already installed on the PC, it is installed automatically. 4. Click “Next”. of 74...
  • Page 51 5. Accept the license agreement, then confirm by clicking “Next”. The installation will terminate, if you do not accept the license agreement. 6. The next installation window lets you review all the relevant information about the software version you are installing. After installation, you can view this information in the "readme.txt"...
  • Page 52 8. Click “Install” to start the installation. IMPORTANT: Make a note of the installation path. The sensor driver is located in a subdirectory. You will need to know this path later when you install the driver. of 74...

  • Page 53: Driver Installation

    IMPORTANT: To install the driver, the user needs to be logged on as an administrator. 1. Connect the USB cable to the torque sensor model 8661 and plug the other end of the USB cable into a free USB port on your PC. If you are using a USB hub, make sure that it can supply sufficient current.
  • Page 54 4. Select “Update Driver Software…“. 5. Select “Browse my computer for driver software“. of 74...
  • Page 55 6. Specify the path to the driver installation files. After installing the DigiVision configuration and analysis software, the driver installation files are located in the folder you specified when installing DigiVision. You can use the "Browse" button to select the correct directory.
  • Page 56 8. Confirm your selection by clicking “Next”. 9. The operating system now confirms that the driver for the torque sensor model 8661 has been installed successfully. 10. Then run the installation for the virtual COM port. of 74...

  • Page 57: Installation For The Virtual Com Port

    8.2.2 Installation for the virtual COM port 1. Open the “Device Manager”. Go to “Start” > “Control Panel” > “Hardware” > “Device Manager”. 2. Right-click on “USB Serial Port”. 3. Click on “Update Driver Software…”. of 74...
  • Page 58 4. Select “Browse my computer for driver software“. 5. Enter the same path you specified in the first part of the installation procedure. You can use the "Browse" button to select the correct directory. of 74...
  • Page 59 8. A new device called "USB Serial Port" appears in “Device Manager”. The COM port listed here is now assigned to the USB torque sensor model 8661, and is always visible when the USB torque sensor model 8661 is plugged into a USB port.
  • Page 60 9. If you are using more than one USB torque sensor model 8661 at the same time on one computer, then each sensor is assigned to a separate COM port. Note: If a previously installed USB torque sensor model 8661 is plugged in again, Administrator rights are no longer needed.

  • Page 61: Data Storage

    Software version & licensing 8.3.1 8661-P001 The USB version of the torque sensor model 8661 is supplied with the free 8661-P001 version of the DigiVision configuration and analysis software. This version provides the following functions: • 1-channel measurement for one sensor.

  • Page 62: 8661-P100

    • Calculation of mechanical power (only for the angle or speed measurement option). *For the USB version of the torque sensor model 8661 without the speed or angle measurement option selected, you can set a measurement rate of up to 2000 measured values per second. If the speed or angle measurement option is selected, a separate measurement rate of 1000 measured values per second is possible for each measurement channel.

  • Page 63: 8661-P200

    8.3.3 8661-P200 DigiVision version 8661-P200 is available as an upgrade for DigiVision version 8661-P100. In addition to the functions in 8661-P100, this version includes the following extra functions: • Configurable extra maths channels. • 32-channel measurement for up to 32 sensors in parallel.

  • Page 64: Licensing

    8.3.4 Licensing To activate your copy of DigiVision, follow these steps: 1. Click “?” > “Licensing”. 2. Enter your activation code. This could look like this: 12345-12345-12345-12345. Make sure, that you enter the activation code exactly as it appears in your software licensing documents. 3.

  • Page 65: Options

    Example 1: For a torque sensor model 8661 with a 1000 Nm measurement range, the large shaft diameter means that it is not possible to use an encoder disk with fewer than 1024 increments. Example 2: For a torque sensor model 8661 with a 0.05 Nm measurement range, an encoder disk with �������� ����...
  • Page 66 If the torque sensor model 8661 includes the speed/angle option, the speed/angle output supplies a 5 V TTL signal. However, you can also use this output as an open collector output. For the USB version of the torque sensor model 8661, the measurement data for the torque and also for speed and angle is transmitted digitally via USB.

  • Page 67: Dual-Range Sensor

    E and pin J. There is no need to provide an additional ground connection. For the USB version of the torque sensor model 8661, the measurement range is switched via DigiVision (see chapter 7.2 “Device settings” on page 33).

  • Page 68: Connection Diagram (Dual-Range Sensor, Not Usb)

    9.2.5 Connection diagram (dual-range sensor, not USB) Diagram 37: Connection diagram dual-range sensor IMPORTANT: Pin E and pin J are the common reference ground for U , the speed measurement, angle measurement and for the range switchover and test input. of 74...

  • Page 69: Status Display (Dual-Range Sensor)

    Yellow LED lit Other extended range. Note: Some models of the torque sensor model 8661 go through a self-test mode lasting 4 seconds after power-up. Once the self-test has finished, all the LEDs light up solidly for about 1 s. of 74...

  • Page 70: Calibration And Adjustment

    8661. 10.1 Factory calibration As part of the traceable burster factory calibration, the torque sensor model 8661 is checked for calibratability, and is then calibrated and provided with a calibration label and a calibration certificate. The burster factory calibration certificate includes the following information as a minimum: •...

  • Page 71: Taking Out Of Use

    • Protect the torque sensor model 8661 from knocks. • Protect the torque sensor model 8661 against bending moments. • Support the torque sensor model 8661. • Do not drop the torque sensor model 8661 under any circumstances. of 74...

  • Page 72: Technical Data

    Technical data Please refer to the enclosed data sheet for the technical specification. The latest version of the data sheet is available at: http://www.burster.de/de/sensoren/drehmoment/p/detail/8661/. 12.1 Electromagnetic compatibility 12.1.1 Interference immunity Interference immunity to EN 61326-2-3:2006 Industrial locations 12.1.2 Emitted interference...

  • Page 73: Accessories

    Accessories Please refer to the enclosed data sheet for detailed information about the accessories. The latest version of the data sheet is available at: http://www.burster.de/de/sensoren/drehmoment/p/detail/8661/. 13.1 Software Please refer to the enclosed data sheet for detailed information about the DigiVision configuration and analysis software.

  • Page 74: Disposal

    Disposal Battery disposal As an end user, you are required by law (battery ordinance) to return all used batteries and rechargeable batteries; the disposal through household waste is prohibited. By buying the herein described device you are concerned by this law. Please dispose of your batteries and rechargeable batteries correctly.

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